Subfloor

ABSTRACT

The invention concerns a subfloor which is provided between a hard base ( 11 ) and a floor such as a laminate or parquet floor resting on the latter, whereby this subfloor is composed of laterally connecting mats ( 9, 10 ) having a core ( 1 ) made of a synthetic foam provided with an underlay ( 2 ) and a top layer ( 3 ) made of a synthetic foil, whereby this underlay ( 2 ) and top layer ( 3 ) represent a flap ( 4, 5 ) which extends over the side edge of said core ( 1 ), so that this flap ( 4, 5 ) overlaps with the mat ( 9, 10 ) connecting onto this side edge.

The invention concerns a mat with an underlay and top layer made of asynthetic foil in between which is provided a core of supple syntheticfoam and which is designed to serve as a subfloor, in particular of alaminate or parquet floor.

When laying a laminate or parquet floor, a subfloor must be providedbetween the latter and the base. This subfloor provides for an acousticand thermal insulation on the one hand, and it prevents moisture fromthe base from getting into contact with the laminate or parquet floor.Moreover, the use of a subfloor makes it possible to compensate forunevennesses which may be found in the base.

According to the state of the art, such a subfloor is formed by applyinga damp-proof synthetic foil on the base so as to form a moisturebarrier, whereby a mat of polyethylene foam is subsequently placed onthis synthetic foil.

Laying such a subfloor is rather time-consuming since, in a first stage,said synthetic foil must be applied whereby, next, in a second stage,the mat of synthetic foam must be laid on this foil.

Thus, the synthetic foil or said mat are frequently damaged while beinglaid, since they only have a limited rigidity. Moreover, when a subflooris provided in a relatively large space, several synthetic foils have tobe laid next to one another, so that moisture from the base canpenetrate in the laminate or parquet floor via the connection betweenthe synthetic foils, as a result of which no perfectly sealed moisturebarrier is obtained.

The invention aims to remedy these disadvantages by providing a mat fora subfloor which can be very easily laid and which offers a betterresistance against damage and which moreover forms an almost perfectmoisture barrier, irrespective of the size of the base.

To this aim, the above-mentioned underlay and top layer have a flapextending laterally in relation to said core.

Practically, the flap of the underlay and the flap of the top layer willextend on one and the same side edge of said core.

According to a preferred embodiment of the mat according to the toinvention, the flap of the underlay is provided on the side edge of saidcore opposite to the side edge where the flap of the underlay extends.

In an advantageous manner, a strip of glue is provided which extends onthe upper side of the mat at a distance from the side edge, situatedopposite to the flap of the top layer, which is smaller than the widthof this flap.

According to a special embodiment, the flap of said top layer is foldeddown on the corresponding side edge up to against the upper side of themat.

The invention also concerns a subfloor which is provided between a hardbase and a floor resting upon the latter, such as a laminate or parquetfloor, which subfloor is composed of laterally connecting mats having acore made of synthetic foam provided with an underlay and a top layermade of a synthetic foil which represent a flap Which extends over theside edge of the core, whereby this flap overlaps with the mat connectedonto this side edge.

According to a preferred embodiment of the subfloor according to theinvention, a strip of glue is provided between said mat and the flap ofthe corresponding connected mat overlapping with it.

According to a further preferred embodiment of the subfloor according tothe invention, the flap of the top layer and that of the underlay extendon one and the same side edge of said mats.

Other particularities and advantages of the invention will become clearfrom the following description of some embodiments of the mat and thesubfloor according to the invention; this description is given as anexample only and does not restrict the scope of the claimed protectionin any way; the reference figures used hereafter refer to theaccompanying drawings.

FIG. 1 is a schematic view in perspective of a first embodiment of themat according to the invention.

FIG. 2 is a schematic view in perspective of a second embodiment of themat according to the invention.

FIG. 3 is a schematic view in perspective of a part of a subflooraccording to the invention.

In the different drawings, the same reference figures refer to identicalor analogous elements.

The mat according to the invention, as represented in FIG. 1, consistsof a strip of a certain length and is formed of a core 1 made of arelatively supple synthetic foam, preferably selected from the group ofpolyolefine foams, such as for example polyethylene foam with closedcells, coated with an underlay 2 and a top layer 3 of a preferablysupple synthetic foil. The underlay 2 and the top layer 3 are fixed tothe core 1 by means of gluing or flame lamination. Further, the underlay2 and preferably also the top layer 3 are impermeable to moisture, andthey are made for example of a polyethylene foil. The thickness of theunderlay 2 and the top layer 3 amounts to, preferably, 30 μm to 250 μmand is, for example, in the order of magnitude of 100 μm to 200 μm, inparticular 150 μm, whereas the core 1 has a thickness of 1.5 to 5 mm andis preferably almost 2 to 3 mm thick. The total thickness of the mat isthus preferably in the order of magnitude of 2 to 3 mm.

The underlay 2 and the top layer 3 are wider than the core 1, so thatthe side edges thereof form a flap 4 and 5 which extend laterally inrelation to the core 1. In the embodiment of the mat according to theinvention represented in FIG. 1, the flap 4 of the underlay 2 and theflap 5 of the top layer 3 extend on one and the same side edge 7 of thecore 1.

Further, on the upper side of the mat is provided a strip of glue 6which extends almost continuously along the side edge 8 thereof oppositeto the side edge 7 where the above-mentioned flap 5 of the top layer 3is provided.

This strip of glue 6 extends at a distance from the side edge 8 which issmaller than the width of this flap 5 of the top layer 3.

In order to simplify the laying of the mat when creating a subfloor, theflap 5 of the top layer 3 is folded down up against the upper side ofthe mat, as represented in FIG. 1.

FIG. 2 represents a variant of the preceding embodiment of the mataccording to the invention. With this mat, the flap 4 of the underlay 2extends on the side edge 8 of the core 1, whereas the flap 5 of the toplayer 3 extends on the opposite side edge 7.

The mat according to the invention is designed to be placed on a hardbase to thus form a subfloor, for example for a laminate or parquetfloor, which is damp-proof and which can compensate for possibleunevennesses in this base.

FIG. 3 represents a subfloor formed of laterally connecting mats 9 and10 which are placed with their underlay 2 on a base 11. The mats 9 and10 correspond to the embodiment of the mat according to the invention,as represented in FIG. 1.

Thus, when creating a subfloor, a first mat 9 is laid on the base 11,whereby the flap 5 of the top layer 3 thereof is folded down up againstthe upper side of the mat 9.

Then, a second mat 10 is laid next to this first mat 9, whereby thecores 1 of these mats connect laterally and the side edge 8 of thesecond mat 10, which does not have any flaps, is connected to the sideedge 7 with the flaps 4 and 5 of the first mat 9.

This second mat 10 hereby partially rests on the flap 4 of the underlay2 of said first mat 9, so that the underlays 2 of the mats 9 and 10overlap.

Finally, the flap 5 of the top layer 3 of said first mat 9 is foldeddown as of the position as represented in FIG. 1 to up against the toplayer 3 of the second mat 10, such that this flap 5 is put into contactwith the strip of glue 6 of the second mat 10.

By making such mats successively connect laterally in this manner, asubfloor is created forming an almost perfect moisture and damp barrier,thus preventing moisture from the base 11 of getting into contact withthe laminate or parquet floor which is to be laid on top of thesubfloor.

The top layer 3 of the mat according to the invention is preferably madeof a synthetic foil with a small coefficient of friction. This makes itpossible, when laying the laminate or parquet floor, to slide theconstituent panels of this floor over the top layer, which considerablysimplifies the laying thereof.

It was found that the mats according to the invention are more rigid andare less easily damaged when laying a subfloor, compared to a plasticfoil or a synthetic foam core when the latter are placed successivelyand as separate on a base.

As the thus obtained subfloor forms a moisture barrier, the risk thatthe laminate or parquet floor will warp or become damaged due to themoisture from the base is practically negligible.

Naturally, the invention is not limited to the above-described mat andsubfloor represented in the accompanying drawings. Thus, said strip ofglue 6 can for example be provided on the underlay 2 of the mat 9, suchthat the latter is joined in a moisture-proof manner to the flap of theunderlay 2 of a connecting mat 10.

In certain cases, a strip of glue is provided on the top layer of themat as well as on the underlay thereof.

The strip of glue can for example also be provided on the side of theflap turned towards the core. Further, a protecting strip is usuallyprovided on the strip of glue 6 which must be removed when laying thesubfloor before joining the connecting mats together via the respectiveflap of the top layer.

The mat according to the invention is advantageously rolled up, in orderto simplify its transport, in a direction across said side edges,whereby the top layer is situated on the inner side of the thus formedroll. When laying the subfloor, these rolls are then unrolled next toone another and they are joined together by unfolding the flap of thetop layer against-the corresponding-strip of glue.

Although the above description concerns a subfloor of a laminate orparquet floor, the mat according to the invention is also suitable to beused as a subfloor for all sorts of floors whereby a moisture barrierand an insulation is to be provided between the base and the floor, suchas for example for cork floors. The mat according to the invention cangenerally be applied for practically all types of sprung floors.

1. A moisture barrier subfloor comprising a mat, the mat comprising: anunderlay and a top layer each made of a synthetic foil in between whichis provided a core of synthetic foam, the underlay and the top layereach having a flap which extends laterally in relation to said core, atleast one area of glue disposed on an exterior surface opposite the coreof at least one of the top layer and the underlay, wherein the at leastone area of glue is not on the flap but is disposed at a location on theexterior surface to receive and secure thereto a flap of an adjacent matof similar configuration, and a removable protective area covering theat least one area of glue.
 2. The mat according to claim 1, wherein theflap of the underlay and the flap of the top layer extend on a same sideedge of said core.
 3. The mat according to claim 1, wherein the at leastone area of glue extends on the top layer at a distance from a side edgesituated opposite to the flap, the distance being smaller than the widthof the flap.
 4. The mat according to claim 1, wherein said core is madeof polyolefin foams.
 5. The mat according to claim 1, wherein saidsynthetic foil has a thickness of 150 μm to 250 μm.
 6. A moisturebarrier subfloor to be provided between a hard base and a floor restingon the latter, the subfloor comprising a plurality of mats of claim 1,wherein the removable protective area is removed so that adjacent matscan be laterally connected with the at least one area of glue of one matreceiving and securing the flap of an adjacent mat and with the core ofone mat contacting only the core or the synthetic foil of an adjacentmat.
 7. The subfloor according to claim 6, wherein the at least one areaof glue is provided on the exterior surface of the at least one mat withthe flap of the adjacent connecting mat in an overlapping relation withthe at least one area of glue.
 8. The subfloor according to claim 6,wherein the flap of the top layer and the flap of the underlay extend onthe same side edge of said mats.
 9. The subfloor according to claim 6,wherein the core of said mats is made of polyolefin foams.
 10. Thesubfloor according to claim 6, wherein said synthetic foil has athickness of 150 μm to 250 μm.
 11. The mat according to claim 5, whereinsaid synthetic foil has a thickness of 200 μm.
 12. The subflooraccording to claim 10, wherein said synthetic foil has a thickness of200 μm.
 13. A mat for use under a floor comprising; a synthetic foamcore laminated to a top layer and a bottom layer, said top and bottomlayers each made of synthetic film, said bottom layer having a flapextending beyond an edge of said core, at least one area of gluedisposed on an exterior surface opposite the core of at least one of thetop layer and the bottom layer, wherein the at least one area of glue isnot on the flap but is disposed at a location on the exterior surface toreceive and secure thereto a flap of an adjacent mat of similarconfiguration, and a removable protective area covering the at least onearea of glue.
 14. The mat of claim 13 wherein said flap is configured toextend over an adjacent mat of similar configuration.
 15. The mat ofclaim 13 wherein both said top and bottom layers have a flap extendingbeyond an edge of said core.
 16. The mat of claim 15 wherein said toplayer and said bottom layer have flaps extending beyond the same edge ofsaid core.
 17. The mat of claim 13 wherein said synthetic foam is apolyolefin foam.
 18. The mat of claim 17 wherein said polyolefin ispolyethylene.
 19. The mat of claim 13 wherein said synthetic film ispolyethylene.
 20. The mat of claim 13 wherein said core has a thicknessof about 1.5 to 5 mm.
 21. The mat of claim 13 wherein said film has athickness of about 30 to 250 μm.
 22. The mat of claim 21 wherein saidfilm has a thickness of about 150 to 250 μm.
 23. A flooring systemcomprising a floor and a moisture barrier subfloor, wherein saidsubfloor includes a plurality of mats of claim 13, wherein the removableprotective area is removed so that adjacent mats can be laterallyconnected with the at least one area of glue of one mat receiving andsecuring the flap of an adjacent mat and with the core of each matcontacting only the core or the synthetic foil of an adjacent mat. 24.The flooring system of claim 23 wherein said flap is configured toextend over an adjacent mat.
 25. The flooring system of claim 23 whereinboth said top and bottom layers have a flap extending beyond an edge ofsaid core.
 26. The flooring system of claim 25 wherein said top layerand said bottom layer have flaps extending beyond the same edge of saidcore.
 27. The flooring system of claim 23 wherein said area of glue iscovered by a removable protective area.
 28. The flooring system of claim23 wherein said synthetic foam is a polyolefin foam.
 29. The flooringsystem of claim 28 wherein said polyolefin is polyethylene.
 30. Theflooring system of claim 23 wherein said synthetic film is polyethylene.31. The flooring system of claim 23 wherein said core has a thickness ofabout 1.5 to 5 mm.
 32. The flooring system of claim 23 wherein said filmhas a thickness of about 30 to 250 μm.
 33. The flooring system of claim32 wherein said film has a thickness of about 150 to 250 μm.
 34. The matof claim 1, wherein the at least one area of glue is at least one stripof glue.
 35. The subfloor of claim 6, wherein the at least one area ofglue is at least one strip of glue.
 36. The mat of claim 13, wherein theat least one area of glue is at least one strip of glue.
 37. Theflooring system of claim 23, wherein the at least one area of glue is atleast one strip of glue.
 38. The mat of claim 1, wherein the flapproximate the at least one area of glue has a surface facing toward thecore that is substantially free of glue.
 39. The mat of claim 38,wherein the flap proximate the at least one area of glue has anothersurface facing away from the core that is also substantially free ofglue.
 40. The mat of claim 1, wherein the at least one area of glueextends along a strip that is substantially parallel to a lateral edgeof the flap.
 41. The mat of claim 40, wherein the at least one area ofglue is disposed adjacent an edge of the mat opposite the flap, suchthat the at least one area of glue is substantially completely coveredby a flap of an adjacent mat of similar configuration that is receivedand secured thereto.
 42. The mat of claim 13, wherein the flap has asurface facing toward the core and another surface facing away from thecore, at least one of the surfaces of the flap being substantially freeof glue.
 43. The mat of claim 13, wherein the at least one area of glueextends along a strip that is substantially parallel to a lateral edgeof the flap and is disposed adjacent an edge of the mat opposite theflap, such that the at least one area of glue is substantiallycompletely covered by a flap of an adjacent mat of similar configurationthat is received and secured thereto.